Method of making corrugated cores



Patented Oct. 31, 1922.,

J. H. SCHLAFLY. METHOD OF MAKING CORRUGATED CORES.

Patented @ct. 3i, lQZE.

JULIUS H. SCHLAFLY, OF CANTON, OHIO, ASSIGNOR T0 UNITED ALLOY STEELCORPO- RATION, OF CANTON,

OHIO, A CORPORATION OF NEW YORK.

METHOD OF MAKING CORRUGATED OORES.

AppIication filed February 23, 1922. Serial No. 538,783.

To all whom it may concern:

Be it known that I, JULrUs- H. SOHLAFLY, a citizen of the United States,residing at Canton, in the county of Stark and State of Ohio, haveinvented a certain new and useful Improved Method of Making Corrugated(lores, of which the following is a specification. v

The invention relates to the manufacture of transversely-corrugatedsheet-metal cores for concrete floor construction; and the object of theimprovement is to form the cores with deeper corrugations than can bemade by ordinary methods, so as to increase the supporting strength ofthe cores.

A common method of making such cores is by a pressing or stampingoperation to form the transverse corrugations at the same time the coreis shaped from a plain sheet of metal, and as the length of the sheet isnecessarily'shortened by the formation of the corrugations of the core,the depth to which the corrugations can be formed is limited and thesupporting strength of the core is likewise limited.

The improved method involves an initial corrugation of a plain sheet soas to accumulate or gather the metal and shorten the sheet to or aboutthe length of the finished core, a subsequent shaping of the core toform the side flanges and partially, form the arch angles while formingdeep corrugations from the gathered metal, followed by a final shapingof the arch angles.

The initial corrugations can be made in any form or of any dimensionswhich will accumulate sufiicient metal to permit the formation of thedesired deep corrugations without any considerable stretching of themetal beyond the necessary tension which .is desirable to take up allthe kinks and bends there may be in the ordinary sheet; and the finalcorrugation of the flanges may correspond to the corrugations in thebody of the core, or may be reversed at the angle of the flange in wellknown manner so as to increase the strength of the flanges; and botharch angles may be finally shaped by a single operation or by separateoperations as may be desired.

The accompanying drawings forming a part hereof illustrate various stepswhich may be employed in carrying out the improved method, in whichdrawings- Figure 1 is a plan of a plain sheet; Fig. 2, a. plan of thesame after it has been initially corrugated;

Fig. 3, an enlarged longitudinal section of the initially corrugatedsheet on line TIL-III, Fig. 2, showing a like section of deepcorrugating dies;

Fig. 4, a transverse section of deep corrugating and partial shapingdies, showing the sheet therein with the flange angles formed and thearch angles partly formed;

Fig. 5, a perspective section of one-half of the lower deep corrugatingand partial shaping die, with half a core shaped therein;

Fig. 6, a transverse section of dies which may be used for finallyshaping both arch angles by a single operation;

Fig. 7, a transverse section of dies which may be used for finallyseparately shaping the arch angles by successive operations and Fig. 8,a perspective view of the completed core, with reversely corrugatedflanges.

Similar numerals refer to similar parts throughout the several figuresof the drawlngs.

A plain sheet 9 is initially formed with transverse corrugations by anywell known rolling, pressing, or stamping operation, so as to accumulateor gather the material uniformly throughout the sheet and reduce itslength to substantially the length of the finished core.

The corrugations may ordinarily be made without much, if any, stretchingof the metal, but for very deep corrugations, the metal can be stretchedto or near its elastic limit; and the character of the corrugations mayvary from the middle to the ends of the sheet, to compensate for theaction of the dies in the succeeding steps of the process.

The shortened sheet 10 may have rounded corrugations 11 of about halfthe depth and width of the deep corrugations 12 to be finally formed, soas to accumulate the necessary metal required for the deep corrugations;but the particular shape and size of the initial corrugations, as shownin Figs. 2 and 3, are not essential to the subsequent steps of theimproved method.

Complementary dies 13 and 13, as shown in Figs. 3, 4 and 5,may beemployed to form the deep transverse corrugations 12 and to shape thelongitudinal'angles 14 of the side flanges 15 and partially shape thelongitudiformed in a continuous series throughout the length of thesheet, and the corrugations of the side flanges 15 may conform to thecorrugations in the body of the core; but the flange corrugations 17,are'preferably reversed at the angle of the flange to avoid a strainingor rupture of the metal at this point, and to increase the strength ofthe flange angle.

The partially formed longitudinal arch angles 16 may be fully formed,both at the same time by a single operation, by complementary dies 18and 18, as shown in Fig. 6; or may be finally formed separately, bycomplementary dies 19 and 19', as shown in Fig. 7; thereby completingthe formation of the core with deep corrugations as shown in F claim:

1. The method of making transverselycorrugated sheet-metal cores forconcrete floor construction and the like, which consists in transverselycorrugating a sheet to accumulate the metal uniformly throughout itslength, then forming a continuous series of deeper corrugations from theaccumulated metal and shaping the sheet to form flarilges along thesides and an intermediate arc 2. The method of makingtransverselycorrugated sheet-metal cores for concrete floor constructionand the like, which consists in transversely corrugating a sheet toaccumulate the metal uniformly throughout its length, then forming acontinuous series of deeper corrugations from the accumulated metal andcontemporaneously shaping the sheet to form flanges along the sides andan intermediate arch.

3. The method of making transversely corrugated sheet-metal cores forconcrete floor construction and the like, which consists in transverselycorrugating a sheet to accumulat the metal uniformly throughout itslength, then forming a continuous series of deeper corrugations from theaccumulated its length then forming a continuous series of deepercorrugations from the accumulated metal and shaping the sheet to fullyform fiange angles along the sides and to partly form intermediate archangles, and then fully forming the .intermediate arch angles.

5. The method of making transverselycorrugated sheet-metal cores forconcrete floor construction and the like, which consists in transverselycorrugating a sheet to accumulate the metal throughout its length, thenforming a continuous series of deeper corrugations from the accumulatedmetal and shaping the sheet to form flanges along the sides and anintermediate arch.

JULIUS H. SCHLAFLY.

